Compact disk package and method of assembling same

ABSTRACT

A storage package for a recording medium configured to resemble a book includes a paper board panel, releasably attached to first and second plastic, recording medium-holding components, each including a planar surface having means on one face for holding a recording. Upstanding wall portions on one of the components nest within the corresponding wall portions of the other component when the components are assembled together. The paper board panel is uncreased, unscored and unfolded and includes first and second panel areas for adhesive attachment of the plastic components. During assembly, the paper board panel is tautly stretched about and adhesively bonded to the assembled plastic components along the faces of the planar surfaces opposite the recording medium holding faces and along a transverse spline edge of the assembled, the creases defining the spline of the book being formed in the paper board panel during adhesive bonding.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to a closable andlatchable storage package for a recording medium and, more particularly,to a package comprising a paperboard cover assembled to multiple plasticdisc holders.

[0003] 2. Description of the Prior Art

[0004] Various types of planar discs are in use at the present time torecord and store information which is to be retrieved by various means,such as by optical or magnetic means. Typical of such discs are compactdiscs in which information is digitally recorded by use of a laser beamand then read optically by a laser beam. Such discs are used to recordaudio information, such as musical renditions, video information such asvisual images and digital information for use as read only and othermemories for use in various applications, such as computer applications.In most instances, at the present time, such discs are sold withinformation already recorded thereon. In other applications, such discsare sold in blank form and are used by the customer to recordinformation thereon. In the latter case, for example, optical discs aresold for use as computer storage media and are used in hard disc storagesystems. As used herein, the term compact disc or CD is intended toencompass all such discs, whatever their size, for all known or proposeduses.

[0005] Compact discs containing laser recorded information are typicallypackaged in injection molded plastic enclosures designed to hold one ormore CDs for protecting the discs during storage and shipment.Enclosures commonly used at the present time, such as the well known“jewel box,” comprise a three piece assembly consisting of a base orbottom element, an insert or tray in the base/bottom element forpositioning and supporting the disc in the base/bottom element, e.g., bya center projection (commonly referred to as a “rosette”) which engagesthe periphery of the aperture in the center of the disc, and a lid orcover which is hinged to the base/bottom element and is closed thereonafter the disc is mounted therein on the tray. Other enclosures utilizeonly two pieces, omit the tray, and position and support the disc viathe center projection directly on the base/bottom element. The enclosureis, typically, at least partially transparent and graphics relating tothe disc and containing trademark and sales promotional information areusually inserted in such a manner as to be visible through theenclosure.

[0006] Except for the printed matter inserted therein, the “jewel box”is entirely plastic. For this reason, as well as because the typicaljewel box requires three separately injection molded elements which mustbe manually assembled, the use of this type of enclosure is relativelyexpensive. Moreover, the use of such an enclosure is believed to beecologically unacceptable by many because the plastic isnon-biodegradable and, in view of the huge volume of such enclosures inuse today, the disposal of these enclosures poses either a real orpotential environmental problem. One solution to both of these problemshas been the development of hybrid packages comprising both paper boardand plastic components. These hybrid packages provide a CD package whichis suitable and attractive for display, sale and storage of compactdiscs, yet which is both simple and inexpensive to manufacture.

[0007] For example, U.S. Pat. No. 4,709,812—Kosterka discloses a compactdisc package formed from a prescored, preprinted unitary blank and atleast one injection molded plastic compact disc holder or trayadhesively adhered to one segment of the blank, the blank being adaptedto fold along fold lines to position a blank segment over the top of thedisc holder to sandwich it, in book style, between the segment to whichit is adhered and the overlying segment. The problem with this type ofarrangement is that the book frequently opens and provides littleprotection for the CD content therewithin. In addition, the Kosterkahybrid packaging typically gives the visual appearance of inexpensivepackaging, which may not be appropriate or desirable for some of themore expensive visual productions provided on DVD.

[0008] In an effort to improve the hybrid packaging and make it moresubstantial, the compact disc holder, instead of being formed merely asa tray, was formed as an unhinged base and cover which were designed tobe separately mounted on facing segments of the blank, on opposite sidesof a spine, such that, when the book was closed about the spine, thecover aligned with the base and latched therewith to maintain the discholder and book closed in order to afford substantial protection to theCD therewithin. Unfortunately, as the book was opened and closed onmultiple occasions the cardboard blank stretched and the originalalignment between the base and lid became difficult to achieve withconsistency, with the result that it became increasingly difficult toreclose and relatch the disc holder.

[0009] Still another effort to solve the problems associated withproducing a high end hybrid packaging involved vacuforming a unitary,side-by-side storage container base and lid interconnected by a spineand injection molding plastic CD trays designed and dimensioned to beinserted into and adhesively adhered within the vacuformed base and lidin conventional manner. The open vacuformed container housing theinjected molded trays is adhesively bonded along its outer surface to apaperboard covering or blank which resembles the covers of a book. Whenthe resulting book is first closed, the vacuformed case breaks along thecreases which attach the spine to the base and lid such that, viewingthe book in its open orientation, the vacuformed container appears to bethree separate pieces separated by paperboard. Unfortunately, the breaksdo not always occur neatly, frequently making for an aestheticallyunpleasing product. Moreover, the container is impractically expensiveto manufacture. First, it is primarily a plastic container, containing aplastic vacuformed skeleton reinforced by injection molded plastic traysadhesively bonded thereto. Second, assembly requires not less than fourseparate and distinct steps, including vacuforming the container,injection molding the trays, adhesively bonding the trays within thevacuformed base and lid and adhesively bonding the paperboard book-likeblank to the exterior surface of the vacuformed container

[0010] It should be apparent, therefore, that efforts to date directedat hybrid packaging suffer from one or more shortcomings which make theresulting CD packaging either unsatisfactory for repetitive use orinsufficiently durable to provide long term protection for the CDcontent of the package. This is because prior art hybrid packaging is,typically, either uneconomical to manufacture and/or unreliable in useand/or does not function to provide adequate protection to the CDcontent of the container, as by readily re-closing and re-latching.Accordingly, there remains a need for a simple, inexpensive tomanufacture, easy to use hybrid CD package which is reliable for useover the long term.

SUMMARY OF THE INVENTION

[0011] It is therefore a primary object of the present invention toprovide a high end CD package, configured to resemble a book, comprisingtwo plastic CD trays which can easily be manufactured by injectionmolding and a paper board cover, where the holder and cover may bereadily assembled to provide a CD packaging characterized by consistenttray aligmnent and latching.

[0012] It is also an object of the present invention to provide animproved plastic and paperboard CD package which is simple, inexpensiveto manufacture and easy to use.

[0013] It is another object of the present invention to provide animproved CD package comprising two plastic CD trays adhesively bonded toa paperboard blank in such a manner that the trays remain in alignmentand snap fit together to the closed position.

[0014] It is still another object of the present invention to provide amethod of assembling an improved CD package comprising two plastic CDtrays adhesively bonded to a paperboard blank wherein the paperboardblank is unscored, unfolded and uncreased prior to adhesive bonding andis stretched and folds/creases are formed therein as the blank isadhesively bonded to the plastic CD trays.

[0015] The foregoing and other objects are achieved in accordance withthe present invention by providing a storage package for a recordingmedium, such as a CD, comprising a paper board component attached to twoplastic, recording medium-holding components, configured to resemble abook, the package including:

[0016] a paper board component defining a flat panel having a pair ofopposed lateral sides and a pair of opposed transverse side which aregenerally perpendicular to said lateral sides, said panel including afirst panel area for attachment of a first plastic, recordingmedium-holding component and a second panel area for attachment of asecond plastic, recording medium-holding component, said first andsecond components being separated by a third panel area for defining thespline of the book;

[0017] first and second plastic components for receiving and holding arecording medium, each of the components defining:

[0018] a generally planar surface having opposite faces for receivingand maintaining a recording medium on a first face thereof, the planarsurface having marginal edges defining the peripheral extent of thesurface;

[0019] upstanding wall portions on the planar surface proximate themarginal edges of the planar surface, the wall portions on the secondcomponent being positioned a greater distance inside the marginal edgesof the planar surface than on the first component such that, when thecomponents are brought together into first face to first face proximity,the wall portions of the second component nest within the wall portionsof the first component with the outside of the wall portions of thesecond component immediately adjacent the inside of the wall portions ofthe first component, the separation between the planar surfaces of thecomponents being determined by the height of the wall portions; and

[0020] means at corresponding locations on the wall portions of thefirst and second components for releasably engaging and latching thefirst and second components together in an assembled configuration;

[0021] the paperboard component being tautly stretched and adhesivelybonded to the assembled components with the creases defining the splineof said book being formed in said paperboard component during adhesivebonding.

[0022] In another aspect of the invention, there is provided a method ofassembling the storage package for a recording medium characterized bythe steps of assembling the first and second components into anassembled configuration and tautly stretching the paper board panelabout and adhesively bonding the panel to the assembled components alongthe faces of the planar surfaces opposite the first face of eachcomponent. The paper board panel is, desirably, unscored, uncreased andunfolded prior to adhesive bonding the panel to the assembledcomponents. Thus, the creases defining the spline of the book are formedin the paper board panel during adhesive bonding.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023]FIG. 1 is a perspective view, viewed from above, of one embodimentof the improved CD package of the present invention in its openposition.

[0024]FIG. 2 is a top plan view of a first element of the plastic CDholder component of the improved CD package of FIG. 1.

[0025]FIG. 3 is a front plan view of the element of FIG. 2.

[0026]FIG. 4 is a top plan view of the second element of the plastic CDholder component of the improved CD package of FIG. 1.

[0027]FIG. 5 is a front plan view of the element of FIG. 4.

[0028]FIG. 6 is a front plan view showing the juxtaposition of the firstand second elements of the plastic CD holder component when the same areassembled and snap fit together.

[0029]FIG. 7 is a top plan view of a blank for the paper board componentof the present invention.

[0030]FIG. 8 is a top plan view of a blank for the preferred embodimentof the paper board component of the present invention.

[0031]FIG. 9 is an intermediate assembly perspective view of thepaperboard cover and the assembled CD holder immediately prior toadhesively bonding these components into the improved CD package of thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0032] A preferred embodiment of the present invention is illustrated inFIGS. 1, 2, 3, 4, 5, 6 and 9 in which there is illustrated an improvedCD package 10. The package includes two injection molded plastic trays12, 13 and a paper board cover 14 which is, in the preferred embodiment,adhesively attached to each of the trays 12, 13 in accordance with thepresent invention in such a manner that the plastic and paper componentsform a CD package, configured to resemble a book, which presents noalignment problems between the trays when the package is repetitivelyopened and closed

[0033] Tray 12 is a rectangular, relatively thin plate-like member whichis formed with a circular recess 20 defined by a circular side wall 22extending downwardly from surrounding planar surface 24 to base 26. Arosette 28 for gripping a CD and holding it within recess 20 is moldedon raised CD seat 30 which, itself, is molded on base 26. Rosette 28 is,typically, a vertical cylindrical section including radially outwardlybiased gripping fingers for engaging the central opening of a CD placedthereon. Raised seat 30 provides a circular surface on which the annulararea of the CD which is immediately adjacent the central disc aperturecan be supported above the base 26. This area of the CD typicallycontains no recorded information and, therefore, contact between the CDin this area and the raised seat will not damage the CD. The CD may alsobe peripherally supported at its outer edges by peripheral shelf 32formed in circular side wall 22. The outer edges of a CD also,typically, contain no recorded information in order to provide furtherassurance that contact of the recorded areas of the CD with the basewill be avoided. Planar surface 24 of tray 12 includes diametricallyopposed finger wells 34 which communicate with the base 26 of recess 20to facilitate a user removing a recording medium from the recess 20.Recess 22, rosette 28 and finger wells 34 are all well known in the CDpackaging art and need not be described in detail herein.

[0034] Referring to FIGS. 1-5, two opposite lateral sides 36, 38, oneconnecting transverse side 40 and upper and lower spaced segments of theopposite transverse side 42 of tray 12 have upstanding wall portions 36a, 38 a, 40 a, 42 a for defining a spacing rim just inside the marginaledges of the tray periphery. As will be seen, when tray 12 is assembledto corresponding tray 13, the wall portions assure a sufficient spacingbetween a CD mounted on the rosette 28 of tray 12 and a CD mounted onthe rosette 28 of tray 13 that neither of the CDs become damaged bycontact with the other. In addition, a plurality of protrusions 44project inwardly from the inside of the wall portions of tray 12 atspaced locations therealong for engaging with corresponding protrusions44 projecting outwardly from the outside of the wall portions on tray 13to permit the trays 12, 13 to snap fit together for defining an openableand closable CD packaging.

[0035] Tray 13 is a relatively thin plate-like member which issubstantially similar to tray 12. The configuration and elements of tray12 apply equally to tray 13 and, therefore, like reference numeralsdenote like parts. The major difference between the trays is that theupstanding wall portions of tray 13 are positioned a greater distanceinside the marginal edge of the tray than on tray 12 such that, whenassembled, the wall portions of tray 13 nest within the wall portions oftray 12 with the outside of the wall portions of tray 13 immediatelyadjacent the inside of the wall portions of tray 12. This is most easilyseen in FIG. 6. In this way protrusions 44 on the inside of the tray 12wall portions engage correspondingly located protrusions 44 on theoutside of the tray 13 wall portions to permit the trays to snap fittogether for forming a CD package which can be maintained in the closedposition.

[0036] Referring now to FIG. 7, the paper board 14 comprises a pluralityof paper panels which are desirably formed from a presized, pre-printedunitary blank 50. In one embodiment of the invention, blank 50 is anunscored, unfolded, uncreased blank onto which the plastic trays areadhesively bonded in the manner hereinafter described to provide, whenthe CD packaging is in the open position, a first panel 52 and a secondpanel 54 separated by a spline panel 56. Most importantly, is that thesepanels are undefined by fold lines or creases prior to adhesivelybonding the blank to the trays. In this embodiment the blank, i.e., thefirst panel and second panel are single ply although, in some instances,it may be desirable for one or both of these panels to be two ormultiple ply. For example, as shown in phantom in FIG. 7 either or bothof the first and second panel areas may be formed as a two ply panel byproviding one or more additional rectangular section 60, 62 ofsubstantially the same size as the panel area it is to reinforce andjoined along one side thereof by fold line or crease 64, 66. Sections 60and/or 62 may be folded over crease 64, 66 and glued to the adjacentsection 52, 54 to form a two ply panel which may be desirable foraesthetic reasons or to enhance the rigidity of the cover for protectingthe CD within the package. Moreover, while a two panel embodiment of aCD package is illustrated and described, it will be appreciated thatsimilar packages utilizing the principles of the present invention maybe formed from a greater number of panels by the inclusion of optionalpanels (not shown) intermediate the base and cover panels. Blank 50 istypically printed with graphics on the outside of the first and secondpanel areas and on the outside of the spline area. If trays 12, 13 areformed of transparent plastic, then it may be desirable to print theinside of the panel areas as well.

[0037] With reference to FIGS. 8 and 9, to assemble the paper board 14and trays 12, 13, in a preferred embodiment, first and second trays 12,13 are assembled to each other by causing the rosettes 28 to face eachother with partial wall segments 42 of tray 12 aligned with thecorresponding segments 42 of tray 13. As the rosettes are pressed towardeach other, as can be seen from FIG. 6, the wall portions of tray 13slide just inside the corresponding wall portions of tray 12 and theprotrusions on like wall portions engage to maintain the assembled CDpackage in the closed position. Blank 50 may be used in its single plyunaltered condition, as shown in FIG. 7. However, it is preferred toadhesively apply paperboard reinforcing sheets 70 to each of the firstand second panel areas and, thereafter, to apply a spine reinforcingstrip 72 overlying the spine area and, desirably, the spine-adjacentmargins of the panel reinforcing sheets 70.

[0038] The assembled trays are supported on one of the lateral sides 36,38 with the paperboard blank 50, prepared as shown in FIG. 8,surrounding the assembled trays in preparation for being adhesivelybonded thereto. Desirably, the edge of the assembled tray packagecorresponding to transverse side 42 serves as the spine of theto-be-assembled hybrid paper-plastic CD package. This is because edge 42is flat by virtue of omitting therefrom the peripheral rim 76 whichextends outwardly from the periphery of the other three sides, 36, 38and 40 of each of trays 12, 13. The purpose of the peripheral rim 76 isto add rigidity to the ultimate package and to provide a rugged area atwhich the user can grasp the CD package for opening and closing it.

[0039] One of the serious deficiencies of prior art hybrid packages hasbeen that prescored fold lines and creases tend to stretch and distortand paperboard covers tend to stretch with constant folding andunfolding when the CD package is made into a book format. After sometime, the alignment between the opposite plastic trays of the book is nolonger reproducible, with the result that the package is no longercapable of latching shut. To overcome this problem, in accordance withthe present invention, the paperboard cover is applied to the assembledtrays in a tautly stretched condition with whatever folds and creasesare necessary to conform the paperboard to the assembled trays beingformed in place as the paperboard is stretched around the assembledtrays. One way of accomplishing this is to tautly stretch the bookcovers, i.e., the first and second panels 52, 54, generallyperpendicularly to and around the spline edge 42 to bring the coverpanels 52, 54 into alignment with and adjacent the undersides 78 of thetrays 12, 13. A plurality of glue posts 68 are provided on the undersideof each tray for receiving adhesive. In addition, dabs of adhesive areapplied to the underside 78 of base 26. After the paperboard coverpanels 52, 54 are tautly stretched around the spline edge 42 they areplaced into adhesive contact with the adhesive on the glue posts 68 andthe underside 78 of the base 26. Upon drying, the paperboard blank 50has already been stretched and the folds and creases necessary fordefining the spline of the book have been formed in place during theadhesive bonding process. When formed in this fashion, the alignmentbetween adjacent trays is not subsequently lost due to stretching andfolding and the resulting packaging, upon drying of the adhesive,exhibits reproducible opening and snap closing.

[0040] While the present invention has been described in terms ofspecific embodiments thereof, it will be understood that no limitationsare intended to the details of contruction or design other than asdefined in the appended claims.

1. A storage package for a recording medium comprising a paper boardcomponent attached to two plastic, recording medium-holding components,configured to resemble a book, said package including: A. a paper boardcomponent defining a flat panel having a pair of opposed lateral sidesand a pair of opposed transverse side which are generally perpendicularto said lateral sides, said panel including a first panel area forattachment of a first plastic, recording medium-holding component and asecond panel area for attachment of a second plastic, recordingmedium-holding component, said first and second components beingseparated by a third panel area for defining the spline of said book; B.first and second plastic components for receiving and holding arecording medium, each of said components defining: (i) a generallyplanar surface having opposite faces for receiving and maintaining arecording medium on a first face thereof, said planar surface havingmarginal edges defining the peripheral extent of said surface; (ii)upstanding wall portions on said planar surface proximate the marginaledges of said planar surface, said wall portions on said secondcomponent being positioned a greater distance inside the marginal edgesof said planar surface than on said first component such that, when saidcomponents are brought together into first face to first face proximity,the wall portions of said second component nest within the wall portionsof said first component with the outside of the wall portions of saidsecond component immediately adjacent the inside of the wall portions ofsaid first component, the separation between the planar surfaces of saidcomponents being determined by the height of said wall portions; and(iii) means at corresponding locations on the wall portions of saidfirst and second components for releasably engaging and latching saidfirst and second components together in an assembled configuration; saidpaperboard component being tautly stretched and adhesively bonded tosaid assembled components with the creases defining the spline of saidbook being formed in said paperboard component during adhesive bonding.2. A storage package, as claimed in claim 1, wherein said generallyplanar surface of each of said components has a circular recess formedtherein for receiving said recording medium and a rosette within saidrecess for releasably holding said recording medium in said recess.
 3. Astorage package, as claimed in claim 2, wherein said generally planarsurface of each of said components further includes diametricallyopposed finger wells communicating with and extending outwardly fromsaid recess for allowing the insertion of fingers therein when removingsaid recording medium from said recess.
 4. A storage package, as claimedin claim 1, wherein said means for releasably latching comprisesprotrusions on the inside of the wall portions of said first trayengaging correspondingly located protrusions on the outside of the wallportions of said second tray.
 5. A storage package, as claimed in claim1, wherein said paper board component has dimensions substantiallycorresponding to the sum of the lateral dimensions of said first andsecond components plus a transversely extending spine panel between thefirst and second components, said spine panel being defined by a firsttransverse crease at the joinder of said first panel area and said spinepanel and a parallel second transverse crease at the joinder of saidspine panel and said second panel area, said creases being formed duringadhesive bonding of said paper board cover to said assembled first andsecond components, said package being pivotable about said creasesbetween a package open orientation wherein said spine and first andsecond panel areas are substantially coplanar for exposing said recessesin said first and second components to enable access thereto and apackage closed orientation wherein said spine panel extendsperpendicularly to the generally planar plastic surfaces of saidcomponents along one transverse side thereof and said first and secondpanel areas overlie the undersides of said generally planar plasticsurfaces to block access to said recesses and to protect the recordingmedia therewithin.
 6. A method of assembling a storage package for arecording medium, configured to resemble a book, comprising: (a) forminga generally rectangular, flat, unscored, uncreased and unfolded paperboard panel having a first panel area for attachment of a first plastic,recording medium-holding component and a second panel area forattachment of a second plastic, recording medium-holding component, saidfirst and second components being separated by a third panel area fordefining the spline of said book; (b) providing first and second plasticcomponents for receiving and holding a recording medium, each of saidcomponents defining: (i) a generally planar surface having oppositefaces for receiving and maintaining a recording medium on a first facethereof, said planar surface having marginal edges defining theperipheral extent of said surface; (ii) upstanding wall portions on saidplanar surface proximate the marginal edges of said planar surface, saidwall portions on said second component being positioned a greaterdistance inside the marginal edges of said planar surface than on saidfirst component such that, when said components are brought togetherinto first face to first face proximity, the wall portions of saidsecond component nest within the wall portions of said first componentwith the outside of the wall portions of said second componentimmediately adjacent the inside of the wall portions of said firstcomponent, the separation between the planar surfaces of said componentsbeing determined by the height of said wall portions; and (iii) means atcorresponding locations on the wall portions of said first and secondcomponents for releasably engaging and latching said first and secondcomponents together in an assembled configuration; (c) assembling saidfirst and second components into an assembled configuration; (d) tautlystretching said paper board panel about and adhesively bonding saidpanel to said assembled components along the faces of said planarsurfaces opposite said first face of each component, the creasesdefining the spline of said book being formed in said paper board panelduring adhesive bonding.
 7. A method, as claimed in claim 6, wherein thesteps of tautly stretching and adhesively bonding comprise tautlystretching said paper board panel about said spline edge, creasing thepaper board panel while tautly stretching it around the spline edge tobring said first and second panel areas into alignment with and adjacentthe opposite faces of said planar surfaces and, while maintaining saidpaper board panel tautly stretched, adhesively adhering it to saidopposite faces of said planar surfaces.
 8. A method, as claimed in claim6, wherein said means for releasably latching comprises protrusions onthe inside of the wall portions of said first tray engagingcorrespondingly located protrusions on the outside of the wall portionsof said second tray.
 9. A method, as claimed in claim 6, including thestep of loading a recording medium into said packaging.
 10. A method, asclaimed in claim 6, including the step of loading graphics into saidpackaging.